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Course notes Section 10

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The purpose of Pipe Sizing is to ensure that:

Under peak demand conditions (when every single
appliance is turned on full blast)
The pressure drop between the meter and each
appliance is no greater than 1mb.
Cooker 12kW

Boiler 18kW

Meter to Boiler
Maximum permitted
pressure drop
Fire 7kW
1mb
Cooker 12kW

Boiler 18kW

Meter to Fire
Maximum permitted
pressure drop
Fire 7kW
1mb
Cooker 12kW

Boiler 18kW

Meter to Cooker
Maximum permitted
pressure drop
Fire 7kW
1mb
Learnatrade.co.uk

Procedure for calculating

Pipe Sizes.

The first thing you have to do is split up

the installation depending on how much
gas each section has to supply at peak
load.
 Under peak load conditions,
section A-B will need to supply Cooker 12kW
the sum of the cooker, boiler,
and fire.
Total 37 kW.

A B

Boiler 18kW

Fire 7kW
 Cooker 12kW

A B

C
Boiler 18kW

Section B-C will need to supply

the sum of the cooker and the
boiler.
Total 30 kW
Fire 7kW
 Cooker 12kW

A B

C
Boiler 18kW
Section B-F will need to supply
the Fire
Total 7 kW
F

Fire 7kW

Section 11
Pages 3 to 8
 Cooker 12kW

A B

C D
Boiler 18kW

Section C-D will need to

supply the Boiler
F Total 18 kW

Fire 7kW
Section C-E will need to
supply the Cooker Cooker 12kW

Total 12 kW E

A B

C D
Boiler 18kW

Fire 7kW
Learnatrade.co.uk

Before we start the explanation of the pipe sizing

process, go to section 10 of your Course notes and
take out the following pages:
Page 10. The discharge rates calculator
Page 11. Piping Plan 1
Page 12. Pipe sizing calculation sheet.
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The pipe sizing calculation sheet.
The column headers tell you what
information should be entered in
each column
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The pipe sizing calculation sheet.
The column headers tell you what
information should be entered in
each column

Handy hint!
In this row, you are told what information goes into the
column below, and in some cases, how you calculate it.
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Ready to go?
This is where we start to calculate the pipe
sizes.
Paper out? Pen poised?
Let’s go!

To get the most out of this training module, it is

essential that you do the calculations yourself as
you go through the module.
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In column 1, make a note of the sections

which are shown on Piping Plan 1

A–B
B-C
B-F
C-E
C-D
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Next, using Piping plan 1, calculate the flow rate – in

Kilowatts – and write them down in column 2.

A–B
B-C
B-F
C-E
C-D
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Section A – B has all three appliances.
The cooker – 12 kW
The gas fire – 7 kW
and the boiler – 18 kW
Giving a total of 37 kW

A–B 37
B-C
B-F
C-E
C-D
Learnatrade.co.uk
Section B - C has two appliances.
The cooker – 12 kW
and the boiler – 18 kW
Giving a total of 30 kW

A–B 37
B-C 30
B-F
C-E
C-D
Learnatrade.co.uk
Section B - F has one appliance.
The fire – 7 kW

Giving a total of 7 kW

A–B 37
B-C 30
B-F 7
C-E
C-D
Learnatrade.co.uk
Section C - E has one appliance.
The cooker – 12 kW

Giving a total of 12 kW

A–B 37
B-C 30
B-F 7
C-E 12
C-D
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Section C - D has one appliance.
The boiler – 18 kW

Giving a total of 18 kW

A–B 37
B-C 30
B-F 7
C-E 12
C-D 18
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The next step in this little drama is to calculate the gas

flow in cubic metres and write it into column 3.

A–B 37
B-C 30
B-F 7
C-E 12
C-D 18
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There are 10.77 kW per cubic metre.

So dividing the Kilowatts in column 2 by 10.77 will give
you the flow rate in cubic metres.

A–B 37
B-C 30
B-F 7
C-E 12
C-D 18
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Work these out using your calculator, and write the

results down in column 3.
Do them all before going on to the next slide.

A–B 37 3.43
B-C 30 2.78
B-F 7 0.65
C-E 12 1.11
C-D 18 1.67
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At this point, you can check that the meter will be able to
carry the load.
Our meter is a U6, which will deliver 6 cubic metres per
hour. The peak load for our system is 3.43 cubic metres,
so the gas meter is ok for this installation.

A–B 37 3.43
B-C 30 2.78
B-F 7 0.65
C-E 12 1.11
C-D 18 1.67
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The next task is to measure the

length of each section of pipe.

There are two sets of measurements – The first

being the measured length of the pipe.
Out on site you would have to measure these
lengths. However in the assessment the pipe
lengths will be given to you.
Look at the lengths given on Piping plan 1 and
write them into column 4 of your Pipe size
calculation sheet
 Piping Plan 1
Cooker 12kW

E
2m
3.5 m 2m
2m

A B

C D
Boiler 18kW

4.5 m

Fire 7kW
Learnatrade.co.uk

Write the measured lengths from Pipework Plan

1 into column 4

A–B 37 3.43 3.5

B-C 30 2.78 2.0
B-F 7 0.65 4.5
C-E 12 1.11 2.0
C-D 18 1.67 2.0
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The next task is to measure the extra

length to allow for fittings

The second set of measurements relates to the

restriction caused by fittings.
For each fitting an allowance of length is made,
depending on the fitting used.
For each elbow, allow 0.5 m
For each formed 90o bend, allow 0.33 m
For each tee, allow 0.5 m
Learnatrade.co.uk

The next task is to measure the extra

length to allow for fittings

The second set of measurements relates to the

restriction caused by fittings.
For each fitting an allowance of length is made,
depending on the fitting used.
For each elbow, allow 0.5 m
For each formed 90o bend, allow 0.33 m
For each tee, allow 0.5 m
Learnatrade.co.uk

The next task is to measure the extra

length to allow for fittings

The second set of measurements relates to the

restriction caused by fittings.
For each fitting an allowance of length is made,
depending on the fitting used.
For each elbow, allow 0.5 m
For each formed 90o bend, allow 0.33 m
For each tee, allow 0.5 m
(You’ll find these allowances on page 4 of Module 10)
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On site, you would physically count the number

and type of fittings.
In the assessment centre, you will either be told
the number and type of fittings, or work them
out yourself from an isometric drawing.
In our example, you are told the number and
type of fittings.
 Cooker 9.5kW

E
2.5 m
3.5 m + 2 4m + 2
elbows and elbows and 2m
1 tee 1 tee

A B

C D
Boiler 15.5kW

3.5 m Additional length

Section A – B
F 2 elbows = 1m
1 tee = 0.5m
Total 1.5 m
Fire 5.5kW
Write this down in
column 5
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You can now calculate the additional lengths for

all the other sections of pipework, and enter
them into column 5.

A–B 37 3.43 3.5 1.5

B-C 30 2.78 2.0 1.5
B-F 7 0.65 4.5 -
C-E 12 1.11 2.0 -
C-D 18 1.67 2.0 -
Learnatrade.co.uk

Adding together columns 4 and 5 will give you

the Effective Length of each section of pipe.
Enter your results into column 6

A–B 37 3.43 3.5 1.5 5.0

B-C 30 2.78 2.0 1.5 3.5
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C-D 18 1.67 2.0 - 2.0
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Calculating pipe size and pressure

loss for each section.
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Calculating pipe size and pressure

loss for each section.

Right! That’s the easy bit done.

Now we go on to calculating the pipe size for
each section of pipework.
Learnatrade.co.uk

Calculating pipe size and pressure

loss for each section.

Right! That’s the easy bit done.

Now we go on to calculating the pipe size for
each section of pipework.

You will also have to calculate the pressure loss

for each section, to make sure that the pressure
loss between meter and each of the appliances
does not exceed 1mb.
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A bit of information for you.

In the real world, it would be very
unusual to go out of your way to
install a couple of metres of 12mm or
10mm pipe into a carcass.
It’s just as easy, and a lot cheaper, to
run that section of tube in 15mm.
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However!
When you are preparing for your
CCN1 assessment, the real world no
longer exists.
Welcome to….
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In Assessment World, it is
absolutely essential that you
specify the pipe diameter
which is right for the amount
of gas required by the
appliance.
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And this is how it’s done!

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Up to this point, you’ve been able to complete

all the columns and rows for the pipework by
referring to Piping plan 1

A–B 37 3.43 3.5 1.5 5.0

B-C 30 2.78 2.0 1.5 3.5
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C-D 18 1.67 2.0 - 2.0

Section 11
Pages 3 to 8
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0

B-C 30 2.78 2.0 1.5 3.5
B-F
But now
7 we’re
0.65 going
4.5 to concentrate
- 4.5 on each section in turn.
12 1.11
C-E
The2.0first one
- being
2.0section A - B
C-D 18 1.67 2.0 - 2.0
You’ll need the Discharge Rates Calculator to work out the
information required to get the correct pipe diameter.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22

B-C 30 2.78 2.0 1.5 3.5
First,
B-F
using
7 your
0.65vast experience
4.5 - in the
4.5 gas industry, you are going to
C-E make
12 an
1.11educated
2.0 guess
- at what
2.0 the pipe size will be.
C-D 18 1.67 2.0 - 2.0
With a total flow rate of 3.43 Cubic Metres, (From column 3)
I think we should be ok with 22mm.
Make a note of the suggested pipe diameter in column 7
Now get out your Discharge Flow Rate Calculator
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Using the Discharge Rate Calculator

The column on the left is the diameter of the Pipe.

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Using the Discharge Rate Calculator

The column on the left is the diameter of the Pipe.

The body of the chart is the amount of gas you want
your pipe to carry per hour in M3
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Using the Discharge Rate Calculator

The top row tells you the maximum pipe length which
will result in a 1mb pressure drop
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22

B-C 30 2.78 2.0 1.5 3.5
B-F 7 0.65Back to
4.5 our pipe
- sizing
4.5 calculation.
What
C-E
we12need1.11
to work2.0out is the
- 2.0
maximum length of a 22mm copper
C-D 18 1.67 2.0 - 2.0
tube carrying 3.43 cubic metres of gas per hour.
Learnatrade.co.uk

Look down the first column until you get to 22mm

Then follow the row across until you come to a number which is equal
to or greater than the volume of gas required for this section of
pipework. In the Case of A – B, this is 3.43 M3/hr
Learnatrade.co.uk

Look down the first column until you get to 22mm

Then follow the row across until you come to a number which is equal
to or greater than the volume of gas required for this section of
pipework. In the Case of A – B, this is 3.43 M3/hr
Learnatrade.co.uk

Warning!
Don’t be tempted by the 3.4 in the next column.
You want a number which is equal to, or greater than 3.43
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Anyway.. On we go.
When you’ve decided on the correct column for the volume required,
you then look at the number at the head of the column. This is the
maximum length of pipe which will carry your volume of gas and have
no more than 1 mb pressure drop.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12

B-C 30 2.78 2.0 1.5 3.5
B-F 7 0.65 4.5 - 4.5
C-E The12reading
1.11from2.0
the Discharge
- rate calculator is 12 metres.
2.0
C-D 18 1.67 2.0 - 2.0
Enter that length into column 8 of your calculation chart
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12

B-C 30 2.78 2.0 1.5 3.5
You
B-F
now
7 have
0.65to work
4.5 out the
- pressure
4.5 drop for your section of
C-E pipework,
12 1.11 which
2.0 has -an effective
2.0 length of 5 metres.
C-D 18 1.67 2.0(as shown
- in2.0
column 6)

Section 11
Pages 3 to 8
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12

B-C 30 2.78 2.0 1.5 3.5
B-F 7 12 metres
0.65 4.5 gives - 1 mb 4.5 pressure drop.
CSo
- Eif you
12divide column
1.11 2.0 6 by column
- 2.08, you will get the pressure loss
C-D 18 1.67 2.0in your- section
2.0 of pipe.

5 divided by 12 equals 0.41 mb pressure loss.

Note the hint in column 9 telling you
Enter this
what into column 9
to do!
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5
B-F 7 0.65 4.5 - 4.5
12
5 divided
1.11
by 12 equals
2.0 -
0.41
2.0
mb pressure loss.
C-E
C-D 18 1.67 2.0 - 2.0

Enter this into column 9

Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
That’s
C-D the
18 first 1.67
length of
2.0pipe sorted,
- you now have to do the same for
2.0
the other sections of pipe.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
For
C - D section
18 B –1.67
C, which
2.0 has 2.78
- cubic
2.0 metres of gas flowing through
it, you would probably suggest 22mm again.
So enter that into column 7.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C -Looking
D 18 at the
1.67Discharge
2.0 rate
- calculator,
2.0 you can see that to get a
flow rate of 2.78 cubic metres an hour, the length of pipe which will
give you a 1 mb pressure drop is 20 metres.
Enter this into column 8
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A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C Now
-D work
18 out the pressure
1.67 2.0 loss
- in2.0
your section of tube by dividing
column 6 by column 8
3.5 / 20 = 0.17 mb pressure drop.
Enter this in column 9
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C-D By adding
18 1.67 up2.0
the pressure
- drop
2.0 for A – B, and B – C,
you can see that the total pressure drop for section A – C is 0.58 mb.
Enter this in column 9 on the B – C row
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C-D By adding
18 1.67 up2.0
the pressure
- drop
2.0 for A – B, and B – C,
you can see that the total pressure drop for section A – C is 0.58 mb.
Enter this in column 9 on the B – C row which keeps track of the
progressive pressure loss in the installation.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5
C-E 12 1.11 2.0 - 2.0
C-D 18 1.67 2.0 - 2.0
The next bit of tube we’re going to work out is the connection to the
fire. 4.5 metres long, and has to supply 0.65 m3 of gas.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15
C-E 12 1.11 2.0 - 2.0
Now in the
C-D 18 real world,2.0you would
1.67 - run
2.0it from the tee to the restrictor
elbow in 15mm and that would be it.

But we’re in Assessment Land, so it has to be done correctly

Enter 15mm into column 7 and we’ll check it out
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Go to 15mm in the pipe diameter column, and then go along the row
until you get to 0.65
The nearest one is 0.68 which allows 30 metres for a 1 mb pressure
drop.
15mm is obviously too big, so check the 12mm readings

Length of pipe in Metres - Copper tube

Pipe
Diameter
mm 3 6 9 12 15 20 25 30

10 0.86 0.53 0.5 0.37 0.3 0.22 0.18 0.15

12 1.5 1 0.85 0.82 0.69 0.52 0.41 0.34
15 2.9 1.9 1.5 1.3 1.1 0.95 0.92 0.68
22 8.7 5.8 4.6 3.9 3.4 2.9 2.5 2.3
28 18 12 9.4 8 7 5.9 5.2 4.7
Discharge of gas flow rate (M3/Hr)
Learnatrade.co.uk

Go to 15mm in the pipe diameter column, and then go along the row
until you get to 0.65
The nearest one is 0.68 which allows 30 metres for a 1 mb pressure
drop.
15mm is obviously too big, so check the 12mm readings

Length of pipe in Metres - Copper tube

Pipe
Diameter
mm 3 6 9 12 15 20 25 30

10 0.86 0.53 0.5 0.37 0.3 0.22 0.18 0.15

12 1.5 1 0.85 0.82 0.69 0.52 0.41 0.34
15 2.9 1.9 1.5 1.3 1.1 0.95 0.92 0.68
22 8.7 5.8 4.6 3.9 3.4 2.9 2.5 2.3
28 18 12 9.4 8 7 5.9 5.2 4.7
Discharge of gas flow rate (M3/Hr)
Learnatrade.co.uk

This shows that you can have 15 metres of 12 mm before you have a
1mb pressure drop.
15mm seems to be a bit too big, so you need to check
Our bitout
of pipe
theisnext
only 4.5 metres, so
diameter let’s work
down, out the
which pressure drop
is 12mm.
in that length.
4.5 / 15 = 0.3 mb

Length of pipe in Metres - Copper tube

Pipe
Diameter
mm 3 6 9 12 15 20 25 30

10 0.86 0.53 0.5 0.37 0.3 0.22 0.18 0.15

12 1.5 1 0.85 0.82 0.69 0.52 0.41 0.34
15 2.9 1.9 1.5 1.3 1.1 0.95 0.92 0.68
22 8.7 5.8 4.6 3.9 3.4 2.9 2.5 2.3
28 18 12 9.4 8 7 5.9 5.2 4.7
Discharge of gas flow rate (M3/Hr)
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 \ 12 15
15 0.3
C-E 12 1.11 2.0 - 2.0
C-D 18 Cross out the
1.67 2.015mm-which2.0
was first suggested, and
replace it with our new suggestion - 12mm
Enter the maximum pipe length in column 8 (15 metres)
Calculate the pressure loss for the section 4.5 / 15 = 0.3
and enter it into column 9.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15 12 15 0.3
C-E 12 1.11 2.0 - 2.0
All that 18
C-D
remains now is
1.67 2.0to check
- the2.0
total pressure drop between the
meter and the fire.
This pipe run is composed of section A – B, and B – F.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15 12 15 0.3 0.71 Y
C-E 12 1.11 2.0 - 2.0
Add
C-D
the 18
pressure
1.67drop2.0
for each- section
2.0 to give the total pressure loss.

0.41 + 0.3 = 0.71 Is this ok?

It certainly is! So put a Y in column 11.
Learnatrade.co.uk

This leaves two pipe sections to complete.

Have a go at them yourself, and when you’ve finished, go on to the
next slide to see if you’ve got it right.

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15 12 15 0.3 0.71 Y
C-E 12 1.11 2.0 - 2.0
C-D 18 1.67 2.0 - 2.0
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15 12 15 0.3 0.71 Y
C-E 12 1.11 2.0 - 2.0 15 12 0.16 0.74 Y
C-D 18 1.67 2.0 - 2.0 15 6 0.33 0.91
So how did you do?
But here’s a thing!
There’s no problem with C – E with a total drop of 0.74
But what about C – D at 0.91?
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15 12 15 0.3 0.71 Y
C-E 12 1.11 2.0 - 2.0 15 12 0.16 0.74 Y
C-D 18 1.67 2.0 - 2.0 15 6 0.33 0.91
There’s something I haven’t told you.
When working out pipe sizes, you have to make an allowance for
future expansion.
So at 0.91 mb drop, there is no room for ‘add on’s.
Learnatrade.co.uk

A–B 37 3.43 3.5 1.5 5.0 22 12 0.41

B-C 30 2.78 2.0 1.5 3.5 22 20 0.17 0.58
B-F 7 0.65 4.5 - 4.5 15 12 15 0.3 0.71 Y
C-E 12 1.11 2.0 - 2.0 15 12 0.16 0.74 Y
- N
C-D 18 1.67 2.0 - 2.0 22 30 0.06 0.64 Y

So what you really need to do is go up a size to 22mm

This gives a total pressure drop of 0.64 which leaves plenty to go at if
there is an additional future load.
Learnatrade.co.uk

That’s the end of this pipe sizing module.

There are a couple of extra copies of the Pipe size
calculation sheet in your Course notes, and you can
always photocopy one if you need more.
If you would like to have a bit more practice at pipe
sizing, you’ll find a Piping layout plan in your Self
assessment pack